Electric connector and method for manufacturing electric connector

Abstract

To provide an electric contact solution in which damping performance and durability under a vibration-prone environment are improved.SOLUTION: An electric connector (100) is constructed so as to be fitted with an opposite electric connector. The electric connector (100) is related with the electric connector (100) comprising: a housing member (101); an electric terminal housed in a terminal cavity (107) corresponded to the housing member (101); and a vibration-prone element (103). In the electric connector (100), the housing member (101) further comprises a lateral groove (117) that crosses the housing member (101) from a housing member outer surface (109) to the housing member inner surface defining the terminal cavity (107) to be corresponded, and the vibration-prone element (103) is arranged to the lateral groove (117).SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an electrical connector including an electrical terminal and an anti-vibration element. The present invention also relates to an electrical connector assembly, a method of assembling the electrical connector assembly, and a method of manufacturing the electrical connector. [Background technology]

[0002] Known in the art are electrical connectors that include a housing member and one or more electrical terminals that are received in corresponding terminal cavities in the housing member and that are configured to make electrical contact with respective mating electrical terminals of a mating electrical connector when the electrical connector is mated with the mating electrical connector.

[0003] The electrical terminals may be fitted into their corresponding terminal cavities in the housing member, for example, by a form-fit or a friction fit. It is preferable to avoid a friction fit of the electrical terminals to reduce the risk of material degradation to both the housing member and the electrical terminals due to frictional strain, which can affect the durability and quality of the electrical contact. Therefore, various form-fit solutions have been devised for fitting the electrical terminals into the connector housing members, including, among others, cantilever-type snap-fit ​​devices.

[0004] However, due to the given manufacturing tolerances of the electrical terminals and the housing members, the snap-fit ​​of the electrical terminals to the housing members still often allows for small relative movements. In high vibration environments, such as near internal combustion engines, the small relative movements can significantly degrade the electrical terminals and / or the housing members. The small relative movements can also increase fretting corrosion of the electrical terminals and mating electrical terminals when the electrical connector mates with a counter electrical connector. Summary of the Invention [Problem to be solved by the invention]

[0005] It is therefore an object of the present invention to provide an electrical contact solution with improved vibration isolation and durability in high vibration environments. [Means for solving the problem]

[0006] This object is achieved by an electrical connector adapted to mate with an electrical counter-connector along a mating direction, the electrical connector comprising a housing member, an electrical terminal accommodated in a corresponding terminal cavity of the housing member, and an anti-vibration element. According to the invention, the electrical connector is characterized in that the housing further comprises a transverse groove running from an outer surface of the housing member to an inner surface of the housing member defining the corresponding terminal cavity, the anti-vibration element being arranged in the transverse groove.

[0007] The transverse grooves traverse the housing from the housing member outer surface to the housing member inner surface that defines the corresponding terminal cavity, thereby forming a space connecting the outside of the housing member to the terminal cavity. By disposing the vibration-isolating element in the transverse groove, the vibration-isolating element can become a direct mechanical link between the outside of the housing member and the terminal cavity that holds the electrical terminal.

[0008] Thus, the anti-vibration element may be sandwiched between the electrical terminal and the actuating device, particularly when the actuating device is positioned along an outer surface of the housing member, which provides additional stability to the electrical terminal in the terminal cavity, particularly in those cases where manufacturing tolerances still allow relative movement between the electrical terminal and the housing member.

[0009] In particular, when the electrical connector mates with the counter electrical connector along the mating direction, the counter electrical connector can be the actuating device that pinches, in particular compresses, the vibration-proof element together with the electrical terminal, so that when the counter electrical connector vibrates differently than the electrical connector, the vibrations of the counter electrical connector can be directly and additionally transferred to the electrical terminal, which can also reduce the risk of fretting corrosion.

[0010] In one aspect, the anti-vibration element may be disposed in the lateral groove such that the anti-vibration element protrudes beyond the outer surface of the housing member, thereby facilitating mechanical access to the anti-vibration element located in the lateral groove.

[0011] In one aspect, an electrical connector can include a plurality of electrical terminals received in a plurality of corresponding terminal cavities in each of the housing members, a transverse groove extending along a periphery of the housing members from an outer housing member surface across the housing members to each of the respective inner housing member surfaces defining the plurality of corresponding terminal cavities, and a vibration isolation element disposed in the transverse groove so as to protrude beyond the outer housing member surface along the periphery.

[0012] In this configuration, a single anti-vibration element can simultaneously interface with multiple terminal cavities holding respective electrical terminals, meaning that the anti-vibration element can serve to stabilize multiple electrical terminals simultaneously.

[0013] In one aspect, the transverse groove may extend along the entire circumference of the housing member, and the vibration damping element is disposed in the transverse groove such that it protrudes beyond an outer surface of the housing member along the entire circumference of the housing member.

[0014] In one aspect, the anti-vibration element may be formed with a shape that conforms to the outer periphery of the housing member such that the anti-vibration element may be conveniently positioned in the transverse groove to interface with each of a plurality of corresponding terminal cavities.

[0015] In one aspect, the housing member can have a rectangular perimeter in a plane perpendicular to the mating direction, and the vibration damping element has a corresponding rectangular ring shape. The ring-shaped vibration damping element can be disposed in a circumferential transverse groove to provide elastic properties for the vibration damping element to apply a uniform inward stabilizing force to the electrical terminals housed in the housing member.

[0016] In one aspect, the anti-vibration element may be an O-ring. Thus, in this configuration, the electrical connector, and in particular the anti-vibration element, is particularly cost-effective to implement.

[0017] In one embodiment, the anti-vibration element may be made of rubber or a thermoplastic elastomer, in particular having a Shore hardness of 50 to 30, preferably 35 to 45. An anti-vibration element constructed in this way is suitable for achieving the desired flexibility and elastic properties without risking damage to the housing members or the electrical terminals.

[0018] In one embodiment, the anti-vibration element may be positioned in the transverse groove so as to contact one or more electrical terminals, such that pressure or force applied to the anti-vibration element is directly and immediately transmitted to the electrical terminals as well, allowing the anti-vibration element and the electrical terminals to move in concert.

[0019] In one aspect, the vibration-damping elements may be disposed in the transverse grooves to frictionally engage one or more electrical terminals, thereby enhancing stability of the electrical terminals in their respective terminal cavities even when the electrical connector is in an unmated state.

[0020] In one aspect, the anti-vibration element can protrude beyond an inner surface of the housing member defining the one or more corresponding terminal cavities into the one or more corresponding terminal cavities, such that when the electrical terminal is engaged, e.g., snap-fitted, into the corresponding terminal cavity, a frictional engagement can be obtained between the anti-vibration element and the electrical terminal.

[0021] In one aspect, the transverse grooves may traverse the housing member in a direction perpendicular to the mating direction, which allows for a more convenient arrangement of the vibration isolation element interfacing with one or more electrical terminals when the electrical terminals are received in a housing member extending parallel to the mating direction, i.e., the distance between the housing member exterior surface and the housing member interior surface defining the corresponding terminal cavity may be reduced.

[0022] In one aspect, each of the one or more electrical terminals may be a socket contact terminal including an inner narrow portion configured to effect electrical contact with a mating pin contact terminal. For each electrical terminal, a transverse groove traverses the housing from an outer housing member surface to a portion of an inner housing member surface defining a corresponding terminal cavity opposite the respective inner narrow portion of the electrical terminal.

[0023] Thus, the mechanical force compresses the anti-vibration element against the electrical terminal, the compression force being applied locally to the inner narrowing of the electrical terminal. That is, the location of the maximum compression force applied to the electrical terminal may be the inner narrowing of the electrical terminal. This inner narrowing includes one or more electrical contacts when the electrical connector is mated with a counter electrical connector. This may reduce fretting corrosion due to micro-movements between the electrical terminal and a mating electrical terminal configured as a contact pin housed in the counter electrical connector. In particular, when the anti-vibration element vibrates in cooperation with the counter electrical connector, the vibrations of the counter electrical connector and the vibrations of the mating electrical terminal are transmitted to the electrical contacts.

[0024] The object of the present invention is also achieved by an electrical connector assembly comprising an electrical connector according to any one of the above aspects of the present invention and a counter electrical connector having a shell member, the counter electrical connector mating with the electrical connector such that the shell member surrounds the housing member, the shell surrounding the housing conveniently interacting with a transverse groove extending along the outer periphery of the housing member of the electrical connector.

[0025] In one aspect of the electrical connector assembly, the counter electrical connector can be mated with the electrical connector such that the anti-vibration element is compressed between the shell member and the one or more electrical terminals, such that the anti-vibration element further stabilizes the electrical terminals in its cavity and, in particular, allows the one or more electrical terminals to vibrate with the counter electrical connector rather than with the housing member of the electrical connector.

[0026] In one aspect of the electrical connector assembly, the shell member may include an inner surface having a chamfer configured to engage the vibration-damping element, particularly for compression of the vibration-damping element between the shell member and one or more electrical terminals when the opposing electrical connector mates with the electrical connector. The chamfer allows for gradual compression of the vibration-damping element as the connectors of the electrical connector assembly mate. This can provide a smoother mating motion.

[0027] The present invention also includes a method of assembling an electrical connector assembly according to one of the preceding aspects, the method comprising the steps of: mating the housing member with the shell member such that the shell member surrounds the housing member; compressing the vibration isolation element between the shell member and the electrical terminal; Includes.

[0028] When the electrical connector assembly is assembled in accordance with this method, electrical contact is achieved between the electrical terminals providing the aforementioned advantages of the present invention.

[0029] In one aspect of the method of assembling the electrical connector assembly, the inner surface of the shell member of the mating electrical connector includes a chamfer, and the compressing step includes compression between the chamfer and the electrical terminal. The chamfer allows for gradual compression of the vibration isolation element as the connectors of the electrical connector assembly mate. This can provide a smoother mating motion.

[0030] The invention also relates to a method for manufacturing an electrical connector, in particular an electrical connector according to one of the above aspects. The method for manufacturing an electrical connector comprises the steps of: providing a housing member, the housing member having a transverse groove extending therethrough from an outer surface of the housing member to an inner surface of the housing member defining a terminal cavity for the electrical terminal; disposing an anti-vibration element in the lateral groove such that the anti-vibration element protrudes beyond an outer surface of the housing member; Inserting the electrical terminal into the terminal cavity; An electrical connector manufactured according to this method is capable of solving the problems of the present invention and, in particular, achieving the corresponding advantages discussed above of the various aspects of the present invention.

[0031] In one aspect of the method for manufacturing the electrical connector, the electrical terminals are inserted into the terminal cavities such that the electrical terminals contact, and in particular frictionally engage, with the anti-vibration element, so that pressure or force applied to the anti-vibration element can be directly and immediately transferred to the electrical terminals, allowing the anti-vibration element and the electrical terminals to move in concert. The frictional engagement allows for increased stability of the electrical terminals in their respective terminal cavities, even when the electrical connector is in an unmated state.

[0032] In one aspect of a method for manufacturing an electrical connector, an electrical terminal is inserted into the terminal cavity such that an inner narrow portion of the electrical terminal configured to achieve electrical contact with a mating electrical terminal is positioned opposite the vibration isolation element and / or the portion of the inner surface of the housing member defining the terminal cavity where the transverse groove traverses the housing member.

[0033] Thus, when a mechanical force compresses the vibration-damping element against the electrical terminal, the compressive force is applied locally to the inner narrow portion of the electrical terminal, which contains one or more electrical contacts when the electrical connector mates with a counter electrical connector, thereby reducing fretting corrosion due to micro-movements between the electrical terminal and a mating electrical terminal configured as a contact pin housed in the counter electrical connector.

[0034] In one aspect of the method for manufacturing an electrical connector, the lateral grooves of the housing member traverse the housing member from an outer housing member surface to a plurality of inner housing member surfaces defining a plurality of corresponding terminal cavities for each of the plurality of electrical terminals, the method further including the additional step of inserting the plurality of electrical terminals into their respective corresponding terminal cavities such that each of the plurality of electrical terminals contacts the vibration isolation element.

[0035] This method is particularly cost effective in terms of both material and manufacturing process costs since a single anti-vibration element can simultaneously interface with multiple terminal cavities which hold respective electrical terminals.

[0036] The foregoing aspects, objects, features and advantages of the present invention will be more fully understood and appreciated upon careful review of the following more detailed description of the presently preferred exemplary embodiments of the invention in conjunction with the accompanying drawings. [Brief description of the drawings]

[0037] [Figure 1] FIG. 1 is an exploded view of an electrical connector according to a first embodiment of the present invention. [Diagram 2] FIG. 2 is an unexploded perspective view of the electrical connector of FIG. 1. [Diagram 3] 2 is a cross-sectional view of a portion of the electrical connector of FIG. 1 in a non-final manufacturing state. [Figure 4] FIG. 4 shows the electrical connector in final manufacturing condition as shown in FIG. [Diagram 5]2 is a cross-sectional view of a portion of an electrical connector assembly including the electrical connector of FIG. 1 in a non-final assembled state. [Figure 6] FIG. 6 shows the same as in FIG. 5 in the final assembled state. [Figure 7] FIG. 7 is a perspective view of the electrical connector assembly of FIGS. 5 and 6. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0038] In the following detailed description of the embodiments, identical reference numbers identified in different figures and / or different parts of the figure description refer to identical elements. Furthermore, unless expressly stated otherwise, the structural features of the objects shown in Figures 1-7 are not drawn to scale.

[0039] The technical features and their associated advantages or effects described in the following description of the embodiments can be combined with or adapted to any aspect or embodiment of the present invention, either together or independently, to produce further possible embodiments or aspects of the present invention.

[0040] An electrical connector according to a first embodiment of the present invention will now be described with reference to Figs. 1 to 4. Fig. 1 shows an exploded view of an electrical connector 100 according to the present invention. According to this first embodiment, the electrical connector 100 is configured for electrical signal applications in vehicles, particularly automobiles. Specifically, the electrical connector 100 is suitable for electrical signal applications in high vibration environments, for example, near or adjacent to an internal combustion engine of an automobile.

[0041] The electrical connector 100 comprises a housing member 101, an anti-vibration element 103, and an outer jacket 105. In this embodiment, the housing member 101 comprises a plurality of, here ten, terminal cavities 107. The terminal cavities 107 extend through the housing member 101 along a mating direction M, which is parallel to a direction x of a Cartesian coordinate system. The electrical connector 100 is configured to mate with a counter electrical connector along this mating direction M. For example, in this embodiment, the electrical connector 100 is configured to mate with a counter electrical connector 501 along the mating direction M. This will be described with reference to Figures 5, 6, and 7.

[0042] The housing member 101 has a housing member outer surface 109. In a plane P perpendicular to the mating direction M, the housing member outer surface 109 defines an outer periphery of the housing member 101. Furthermore, in this embodiment, the housing member 101 has a box-like, i.e., approximately rectangular, shape. Thus, in the plane P perpendicular to the mating direction M, the housing member 101 may have a substantially rectangular perimeter, in particular a rectangular perimeter with rounded corners 111.

[0043] The outer casing 105 has a cylindrical shape that defines an interior space 113. As shown in Fig. 2, the housing member 101 is configured to fit into the interior space 113 such that the outer casing 105 surrounds the housing member 101. The outer casing 105 further includes a connector position assurance (CPA) device 115 configured to ensure the position of the electrical connector relative to a counter electrical connector when the electrical connector and the counter electrical connector mate. Specifically, the CPA device 115 is configured to lock the electrical connector 100 in a correct mating position with a counter electrical connector, such as the counter electrical connector 501.

[0044] The housing member 101 comprises a transverse groove 117. The transverse groove 117 extends along the outer periphery of the housing member 101. In particular, the transverse groove 117 extends along the entire circumference of the housing member 101, in particular along the entire rectangular periphery in a plane P' perpendicular to the mating direction M. As shown in FIG. 1, the transverse groove 117 has a width W, i.e. an extent along the mating direction M, corresponding to 1% to 10% of the extent along the mating direction M of the housing member 101. Alternatively or additionally, the transverse groove 117 has a height H, i.e. a width W, corresponding to 80% to 120% of the extent in a direction O perpendicular to the mating direction M and parallel to the direction y of the Cartesian coordinate system of the terminal cavity 107.

[0045] Transverse grooves 117 traverse housing member 101 from the exterior of housing member 101 toward the interior of housing member 101 to each of the terminal cavities 107. Specifically, transverse grooves 117 traverse housing member 101 from housing member outer surface 109 to each housing member inner surface 301 that defines a respective terminal cavity 107 formed in housing member 101. Housing member inner surfaces 301 are not visible in Figures 1 and 2, but are shown in Figures 3-6 and will be described below with reference thereto.

[0046] The electrical connector 100 of the first embodiment further includes ten electrical terminals 300, each of which is received in a corresponding one of the ten terminal cavities 107. Although the electrical terminals 300 are not visible in FIG. 1 or FIG. 2, the electrical terminals 300 are shown in FIG. 3-FIG. 6 and will be described with reference to those figures. In an alternative embodiment, some of the terminal cavities 107 may not hold electrical terminals. In other words, it is not necessary for all of the plurality, here ten, of the terminal cavities 107 to receive a respective electrical terminal. Instead, the electrical connector 100 may have a number of electrical terminals that is less than the number of terminal cavities 107, for example, only one, two, four, five, or eight electrical terminals, with one to up to nine of the terminal cavities 107 being empty without housing a respective electrical terminal.

[0047] The anti-vibration element 103 is configured as an elastic band that can be put on the housing member 101. Here, the anti-vibration element 103 has a rectangular ring shape that matches the outer periphery, here the rectangular circumferential extent, of the housing member 101. The anti-vibration element 103 is configured such that, in the unstretched rest state, the anti-vibration element 103 has an inner surface area A that is smaller than the rectangular cross section of the housing member 101, both in the outer plane P of the groove 117 and in the inner plane P' of the groove 117.

[0048] Preferably, the anti-vibration element 103 has a Shore hardness of 50 to 30, preferably 35 to 45, for example here 40. In a variant, the anti-vibration element 103 may instead be torus-shaped or doughnut-shaped. In one example, a commercially available O-ring joint may be used as anti-vibration element 103.

[0049] The housing member 101, anti-vibration element 103, and jacket 105 are preferably manufactured from materials designed for operating temperatures of at least 125° C., preferably at least 150° C. The anti-vibration element 103 may be integrally molded, preferably from rubber or a thermoplastic elastomer. The housing member 101 may be molded from polybutylene terephthalate (PBT).

[0050] Housing member 101 also includes corresponding snap-fit ​​openings 119 for each terminal cavity 107 to enable snap-fit ​​locking of electrical terminals 300 with their corresponding terminal cavities 107. This feature will be further explained with reference to Figures 3 and 4.

[0051] 2 shows a perspective view of the electrical connector 100 in an assembled delivery state. The housing member 101 fits into the housing 105 such that a mating gap 200 is formed between the housing member outer surface 109 and the housing inner surface 201. The mating gap 200 has a mating gap opening 203 facing in a mating direction M. The mating gap 200 is configured to receive a shell member of a mating electrical connector through the mating gap opening 203, such as the shell member 503 shown in FIGS. 5 and 6, when the electrical connector 100 mates with the mating electrical connector.

[0052] The terminal cavities 107 are arranged in the housing member 101 in two parallel rows R1, R2 of five terminal cavities each. The rows R1, R2 extend in a direction perpendicular to the mating direction M. In one variant, the housing member according to the invention may comprise only one terminal cavity. In other variants, the housing member according to the invention may comprise a different number of terminal cavities, for example 2, 4, 7 or 20 terminal cavities, arranged in one row or in two rows such as rows R1, R2. The number of terminal cavities is preferably at least as many as the number of electrical terminals.

[0053] 2, the anti-vibration element 103 is disposed in the lateral groove 117. Specifically, the anti-vibration element 103 extends circumferentially in a plane P' perpendicular to the fitting direction M of the housing member 101 in the lateral groove 117. Because the anti-vibration element 103 has an inner surface area A in the inner plane P' of the groove 117 that is smaller than the rectangular cross section of the housing member 101, the anti-vibration element 103 is in an elongated state when disposed in the lateral groove 117.

[0054] As will be further described with reference to Figure 3, the vibration-proof element 103 is disposed in the lateral groove 117 so as to protrude beyond the housing member outer surface 109. Specifically, Figure 2 shows how the vibration-proof element 103 is disposed in the lateral groove 117 so as to protrude beyond the housing member outer surface 109 into the mating space 200 along at least a portion of the rectangular perimeter of the housing member 101.

[0055] Figures 3 and 4 show the same cross-sectional view of a portion of electrical connector 100 taken along cross-sectional view line V shown in Figure 1. In Figure 4, electrical connector 100 is in a final manufacturing condition, whereas in Figure 3, electrical connector 100 is in a non-final manufacturing condition. In particular, looking at Figure 3, electrical terminal 300 is not fully inserted and locked into housing member 101.

[0056] As previously mentioned, the electrical connector 100 includes ten electrical terminals 300, one for each terminal cavity 107. The ten electrical terminals 300 are structurally identical and identically positioned in their corresponding terminal cavities 107 to mate with mating electrical terminals of a counter electrical connector when the electrical connector 100 mates with the counter electrical connector along a mating direction M.

[0057] In this embodiment, each of the electrical terminals 300 and each of the terminal cavities 107 are identical and their features and effects correspond to each other, so this disclosure is limited to describing the features and effects of one terminal cavity 107 and one electrical terminal 300.

[0058] 3 shows an electrical terminal 300 partially inserted into a corresponding terminal cavity 107 in a mating direction M. The cavity 107 is defined by a housing member inner surface 301 and extends inwardly of the housing member 101 along the mating direction M. In this embodiment, the electrical terminal 300 is stamped from conductive sheet metal. The electrical terminal 300 includes a crimp portion 303 configured to be crimped to an electrical conductor and a contact portion 305 configured to make electrical contact with a mating electrical terminal. The crimp portion 303 is joined to the contact portion 305 vertically in the mating direction M.

[0059] In this embodiment, the electrical terminals 300 are socket contact terminals, i.e., female contacts, and are therefore configured to receive pin contact terminals, i.e., male contacts, when the electrical connector 100 mates with a mating electrical connector. Preferably, the electrical terminals 300 are copper contacts having a tin, silver, or gold coating.

[0060] The electrical contact 300 includes a resilient lance 307 that projects outwardly transversely to the mating direction M and is configured as a cantilever snap-fit ​​device. In the partially inserted view of Figure 3, the electrical terminal 300 is in an intermediate insertion state where the resilient lance 307 has not yet reached the snap-fit ​​opening 119. Thus, the resilient lance is still bent downwards, i.e., inwardly towards the body of the electrical terminal 300, by the housing member inner surface 301 and the electrical terminal 300 is not locked to the housing member 101.

[0061] The electrical terminals include an inner narrow portion 309. The inner narrow portion 309 is configured to provide electrical contact with a mating pin contact terminal when the electrical connector 100 is mated with a counter electrical connector.

[0062] The transverse groove 117 extends through the housing member 101 from the exterior of the electrical connector 100 toward the terminal cavity 107 in a direction O perpendicular to the mating direction. Specifically, the transverse groove 117 traverses the housing member 101 from the housing member outer surface 109 to the housing member inner surface 301 that defines the terminal cavity 107.

[0063] The vibration-damping element 103 is disposed in the lateral groove 117 so as to protrude beyond the housing member outer surface 109. Specifically, the vibration-damping element 103 is disposed in the lateral groove 117 so as to protrude beyond a front portion 311 of the housing member outer surface 109, the front portion 311 being adjacent to the lateral groove 117 on a side facing the mating direction M. The front portion 311 extends in the mating direction M from the lateral groove 117 to a distal end 313 of the housing member 101. The vibration-damping element 103 protrudes beyond the front portion 311 by a distance D1.

[0064] Figure 4 shows a view corresponding to Figure 3, in which the electrical connector 100 is in a final manufacturing state, in particular, the electrical terminals 300 are fully inserted into the terminal cavities 107, and the electrical terminals 300 are properly received in the terminal cavities 107 and locked, in particular snap-fit, into the housing member 101.

[0065] That is, the electrical terminal 300 has been inserted further into the terminal cavity 107 in the mating direction M, and the resilient lance 307 has moved to a position where it can extend into the snap-fit ​​opening 119. Figure 4 shows how the resilient lance 307 has returned outward to its rest position, locking the electrical terminal 300 in the housing member 101 between the narrow terminal cavity opening 400 and the snap-fit ​​stop surface 401 of the snap-fit ​​opening 119.

[0066] In the final manufactured state shown in Figure 4, the electrical terminal 300 is frictionally engaged with the anti-vibration element 103 located in a transverse groove 117 which traverses the housing member 101 into the terminal cavity 107. As can be seen in Figure 4, the transverse groove 117 traverses the housing member 101 to a portion of the housing member inner surface 301 which faces the inner narrow portion 309 of the electrical terminal 300 when said terminal 300 is fully inserted into the terminal cavity 107.

[0067] 4, the electrical terminal 300 is frictionally engaged with the anti-vibration element 103 located in the transverse groove 117 such that the electrical terminal 300 is further stabilized in the terminal cavity 107. In particular, the electrical terminal 300 is frictionally engaged, inter alia, with the inner narrowed portion 309 of the electrical terminal 300. This allows the electrical terminal 300 to be advantageously stabilized in electrical contact when mated with a mating pin contact terminal.

[0068] The anti-vibration elements 103 are disposed in the transverse grooves 117 along the entire periphery of the housing member 101. The anti-vibration elements 103 are therefore in similar contact, and in particular frictional engagement, with each of the ten electrical terminals 300 disposed in the respective terminal cavities 107 in both rows R1 and R2.

[0069] In the first embodiment of the present invention currently being described, the anti-vibration element 103 projects only slightly into the terminal cavity 107 (not visible in Figures 3 and 4), which allows for a light frictional engagement between the anti-vibration element 103 and the electrical terminal 300. However, in a variant, the anti-vibration element may be disposed in the transverse groove such that it projects a predetermined distance, for example distance D1, into the terminal cavity, i.e. extends beyond the inner surface of the housing member.

[0070] A method for manufacturing an electrical connector according to a second embodiment of the present invention will now be described with reference to Figures 1 to 4. The method according to the second embodiment described below is a method for manufacturing the electrical connector 100 already described above.

[0071] The method begins at step A with providing a housing member 101. As previously described with reference to Figures 1-4, the housing member 101 includes a transverse groove 117 that traverses the housing member 101 from a housing member outer surface 109 to at least one of the housing member inner surfaces 301 that define the terminal cavities 107.

[0072] In step B, as will be explained with reference to Figures 3 and 4, the anti-vibration element 103 is placed in the transverse groove 117 such that the anti-vibration element 103 protrudes beyond the housing member outer surface 109, in particular beyond the front portion 311. For this purpose, the anti-vibration element 103 is elastically stretched, for example manually, so that it slides over the housing member outer surface 109 and into the transverse groove 117. As mentioned above, the anti-vibration element 103 is dimensioned such that it contracts inwardly when it reaches the transverse groove 117. This allows the anti-vibration element 103 to be firmly secured in the transverse groove 117 and to provide an inward force that stabilizes the electrical terminal 300.

[0073] In step C, the electrical terminal 300 is inserted into the corresponding terminal cavity 107 along the mating direction M such that the electrical terminal 300 contacts the anti-vibration element 103. As specifically described above, the electrical terminal 300 is inserted into the terminal cavity 107 in the mating direction M until said electrical terminal 300 is snap-fitted into the housing member 101 and the inner narrow portion 309 of the electrical terminal 300 faces the anti-vibration element 103 in frictional engagement.

[0074] An electrical connector assembly according to a third embodiment of the present invention will now be described with reference to Figures 5, 6 and 7. The electrical connector assembly 500 of the third embodiment comprises the electrical connector 100 of the first embodiment of the present invention and a counter electrical connector 501. The counter electrical connector 501 is configured to mate with the electrical connector 100 to achieve electrical contact between the ten electrical terminals 300 and the ten mating electrical terminals 503 of the counter electrical connector 501.

[0075] Figures 5 and 6 show cross-sectional views of a portion of the electrical connector assembly 500 along the cross-sectional line V shown in Figure 1. Specifically, Figures 5 and 6 show the same cross-sectional views of a portion of the electrical connector 100, as seen in Figures 3 and 4, but in different mated states with a counter electrical connector 501. In Figure 6, the electrical connector assembly 500 is in a final assembled state, i.e., the connectors 100, 501 are fully mated, whereas in Figure 5, the electrical connector assembly 500 is not yet fully assembled. In Figure 5, the electrical connector assembly 500 is in an intermediate mated state.

[0076] 5 shows a shell member 503 of a mating electrical connector 501. The shell member 503 is configured as an enveloping shell, as can be seen in FIG. 7. The shell member 503 includes an inner surface 505 extending along a direction parallel to the mating direction M and configured to mate with the housing member outer surface 109. The inner surface 505 of the shell member 503 includes a stop step 507 and a chamfer 509. The stop step 507 is closer to the distal end 511 of the shell member 501 than the chamfer 509. The chamfer 509 is configured to narrow the shell space 513 of the shell member 503 in the mating direction M, i.e., away from the distal end 511.

[0077] The counter electrical connector 501 further includes at least one, here ten, mating electrical terminals 515. The mating electrical terminals 515 are pin contact terminals configured to be received in corresponding socket contact terminals such as the electrical terminals 300. In this embodiment, the mating electrical terminals 515 are all identical and are correspondingly arranged to mate with the corresponding electrical terminals 300. In the following, only one of the mating electrical terminals 515 and its mating will be described.

[0078] 5, the electrical connector 100 is plugged over the counter electrical connector 501 in the mating direction M such that the housing member 101 is partially inserted into the counter electrical connector 501. That is, the shell member 503 has partially slid into the mating space 200.

[0079] Thus, the shell member 503 is sliding over the housing member outer surface 109 of the housing member 101 of the electrical connector 100, except that the stop step 507 has not yet abutted and the chamfer has not yet reached the vibration isolation element 103. The pin terminal 515 has partially entered the electrical terminal 300 through the narrow terminal cavity opening 400.

[0080] 6, the electrical connector assembly 500 is in a final assembly state. That is, the electrical connector 100 and the counter electrical connector 501 are fully mated. In particular, as the electrical connector 100 moves further in the mating direction M, the housing member 101 moves further into the shell space 513, and the shell member 503 also slides further along the housing member outer surface 109. The shell member 503 slides along the housing member outer surface 109 until the stop step 507 abuts against the stopper 600 protruding outward from the housing member 101.

[0081] At the same time, the chamfer 509 reaches and slides over the anti-vibration element 103. Because the chamfer 509 narrows the shell space 515 in the mating direction M, the chamfer 509 engages the anti-vibration element 103, which protrudes outwardly beyond the housing member outer surface 109 of the housing member 101. Because the shell space 515 defined by the shell members 503 is narrowed by the chamfer 509, further mating movement pushing the connectors 100, 501 towards each other forces the anti-vibration element 103 deeper into the lateral groove 117.

[0082] In particular, the shell member 503 in the mated electrical connector assembly applies a compressive force F perpendicular to the mating direction M to the anti-vibration element 103, forcing the anti-vibration element 103 into the transverse groove 117 and against the electrical contacts 300. In other words, the anti-vibration element 103 is compressed and sandwiched between the shell member 503 and the electrical contacts 300. The chamfer 509 allows a gradual increase in the compressive force F up to its maximum value as the anti-vibration element 103 moves the chamfer 109 in the mating direction M.

[0083] 6 shows the fully mated state, where the pin terminal 515 has moved further into the electrical terminal 300 to make electrical contact at the inner narrowing 309. When the vibration isolation element 103 is compressed between the shell member 503 and the electrical contact 300, a direct mechanical link is established between them, which further stabilizes the electrical terminal 300 in its terminal cavity 107 and reduces the possibility of micro-movement of the electrical terminal 300 relative to the housing member 101 that may exist after snapping the electrical terminal 300 onto the terminal 107 due to manufacturing tolerances.

[0084] Additionally, since a direct mechanical link is established between the electrical terminal 300 and the shell member 503, vibrations of the counter electrical connector 501 (which may be different from vibrations of the housing member 101 of the electrical connector 100) can be transmitted to the electrical terminal 300. That is, the electrical terminal 300 can advantageously vibrate together with the counter electrical connector 501 and its mating electrical terminal 515. The cooperative vibration of the electrical terminal 300 and the electrical terminal 515 reduces fretting corrosion.

[0085] Figure 7 shows a perspective view of the electrical connector assembly of Figures 5 and 6. As can be seen in Figure 7, the electrical connector 100 is connected to the counter electrical connector 501 so as to receive the shell member 503 in the mating space 200. In this way, the shell member 503 surrounds the periphery of the housing member 101 along the housing member outer surface 109 thereof.

[0086] Thus, the shell member 503 may apply a compressive force F along the entire periphery of the housing member 101, and in particular along the entire periphery of the vibration isolation element 103. In this manner, the shell member 503 also compresses the vibration isolation element 103 on one side against each of the other sides of the ten electrical terminals 300 in the corresponding terminal cavities 107.

[0087] In view of the electrical connector assembly 500 described above, a method of assembling an electrical connector assembly according to a further, i.e. fourth, embodiment of the invention will now be described. The method according to the fourth embodiment described below is a method of assembling an electrical connector assembly 500 having the features already described above.

[0088] A method of assembling an electrical connector assembly according to the fourth embodiment begins with step D of mating housing member 101 and shell member 503 such that shell member 503 surrounds housing member 101. In particular, electrical connector 100 is connected to a counter electrical connector 501 such that shell member 503 is inserted into mating space 200 and housing member 101 is inserted into shell space 515. This causes inner surface 505 to slide around housing member outer surface 109 of housing member 101.

[0089] The method according to the fourth embodiment further includes a step E of compressing the vibration-damping element 103 between the shell member 503 and the electrical terminal 300. The chamfered portion 509 narrows the shell space 515, so that the inner surface 505 of the shell member 503 engages with the vibration-damping element 103. Specifically, the shell member 503 applies a compressive force F to the vibration-damping element 103 in a direction perpendicular to the mating direction M and against the electrical terminal 300. That is, the vibration-damping element 103 is sandwiched between the shell member 503 and the electrical terminal 300.

[0090] Each of the above-described embodiments of the present invention provide electrical contact solutions with improved vibration isolation and durability in high vibration environments. [Explanation of symbols]

[0091] 100 Electrical terminal 101 Housing member 103 Anti-vibration elements 105 Outer cover 107 Terminal Cavity 109 Housing member outer surface 111 Rounded corners of housing parts 113 Interior space of the envelope 115 CPA Device 117 Yokomizo 119 Snap-fit ​​opening 200 Mating gap 201 Inner surface of outer jacket 203 Fitting gap opening 300 Electrical terminals 301 Housing member inner surface 303 Crimping section 305 Contact part 307 Elastic Lance 309 Inner narrow part 311 Front of outer surface of housing member 313 Distal end of outer surface of housing member 400 Narrow terminal cavity opening 401 Snap-fit ​​stop surface 500 Electrical Connector Assembly 501 Counterpart Electrical Connector 503 Shell member 505 Inner surface of shell member 507 Stop step formed on the inner surface of the shell member 509 Chamfered portion formed on the inner surface of the shell member 511 Distal end of shell member 513 Shell Space 515 Counterpart Electrical Terminal 600 Stopper A is the inner surface area of ​​the vibration isolation element D1 Outer projection distance of vibration isolation element F Compressive force H Terminal cavity height M Mating direction O Orthogonal to the mating direction P, P' Plane perpendicular to the mating direction R1, R2 Terminal Cavity Row V section line

Claims

1. 1. An electrical connector configured to mate with a counter electrical connector (501) along a mating direction (M), comprising: The electrical connector (100) comprises a housing member (101), one electrical terminal (300) accommodated in a corresponding terminal cavity (107) of the housing member (101), and a vibration isolation element (103). The housing member (101) further includes a transverse groove (117) extending across the housing member (101) from a housing member outer surface (109, 311) to a housing member inner surface (301) that defines the corresponding terminal cavity (107); 4. An electrical connector, comprising: a first end of said first connector and a second end of said first connector;

2. 2. The electrical connector of claim 1, wherein the vibration isolation element (103) is disposed in the transverse groove (117) such that the vibration isolation element (113) protrudes beyond the housing member outer surface (311, 109).

3. a plurality of said electrical terminals (300) received in a plurality of corresponding terminal cavities (107) of each of said housing members (101); the transverse groove (117) extends along an outer periphery, in particular the entire periphery, of the housing member (101) across the housing member (101) from the housing member outer surface (109) to each of the housing member inner surfaces (301) that define the corresponding terminal cavities (107); 3. The electrical connector according to claim 1 or 2, wherein the vibration-damping element (103) is arranged in the transverse groove (117) so as to protrude beyond the housing member outer surface (109, 311) along the outer periphery, in particular the entire periphery, of the housing member (101).

4. 4. An electrical connector as claimed in claim 1, wherein the vibration-damping element (103) is formed in a shape that matches the outer periphery of the housing member (101), in particular the housing member (101) has a rectangular periphery in a plane (P, P') perpendicular to the mating direction (M) and the vibration-damping element (103) has a matching rectangular ring shape.

5. 5. The electrical connector according to claim 1, wherein the anti-vibration element (103) is arranged in the transverse groove (117) so as to contact, in particular frictionally engage, one or more of the electrical terminals (300), and in particular the anti-vibration element (103) protrudes further into the one or more corresponding terminal cavities (107) than the housing member inner surface (301) that defines the one or more corresponding terminal cavities (107).

6. each of the one or more electrical terminals (300) being a socket contact terminal (300) having an inner narrow portion (309) configured to provide electrical contact with a mating pin contact terminal (515); 6. The electrical connector of claim 1, wherein for each electrical terminal (300), the transverse groove (117) traverses the housing member (101) from the housing member outer surface (109) to a portion of the housing member inner surface (301) defining the corresponding terminal cavity (107) that faces the inner narrow portion (309) of each of the electrical terminals (300).

7. 7. An electrical connector assembly comprising the electrical connector (100) of any one of claims 1 to 6 and a counter electrical connector (501), the counter electrical connector (501) comprising a shell member (503); The mating electrical connector (501) mates with the electrical connector (100) such that the shell member (503) surrounds the housing member (101) and the vibration isolation element (103) is compressed between the shell member (503) and one or more of the electrical terminals (300).

8. 10. The electrical connector assembly of claim 9, wherein the shell member (503) comprises an inner surface (505) having a chamfer (509) configured to engage the vibration isolation element (103).

9. 9. A method for assembling the electrical connector assembly of claim 7 or 8, comprising the steps of: fitting the housing member (101) and the shell member (503) together such that the shell member (503) surrounds the housing member (101); compressing (F) the vibration isolation element (103) between the shell member (503), in particular the chamfer (509) of the inner surface (505) of the shell member (503), and the electrical terminal (300); A method comprising:

10. A method for manufacturing an electrical connector, in particular an electrical connector (100) according to any one of claims 1 to 8, comprising the steps of: providing a housing member (101) having a transverse groove (117) extending across said housing member (101) from a housing member outer surface (109) to a housing member inner surface (301) defining a terminal cavity (107) for an electrical terminal (300); disposing the anti-vibration element (103) in the transverse groove (117) such that the anti-vibration element (103) protrudes beyond the housing member outer surface (109, 311); inserting said electrical terminal (300) into said terminal cavity (107) so that said electrical terminal (300), in particular an inner narrowed portion (309) of said electrical terminal (300) adapted to achieve electrical contact with a mating electrical terminal (515), comes into contact, in particular frictional engagement, with said vibration-proof element (103); A method comprising:

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